Factory automation control method

ABSTRACT

Disclosed is a factory automation method in which constitution and setting of all devices for a process unit are carried out on a computer. The method includes the steps of: constituting and setting various devices for a process unit on a computer display; grouping the various devices into a transfer line, a heating line and a cooling line; selecting at least one among the three grouped lines to set a control loop for a parameter including temperature, pressure, flow rate, pH and level, and dropping; performing input relating to a process operation; executing a simulated operation and confirming an input error; and on-line connecting the various devices with the computer and normally operating the various devices.

TECHNICAL FIELD

[0001] The present invention relates to a factory automation controlsystem and method, and more particularly, to a factory automation systemand method in which all processes in a factory are automated by using acomputer.

BACKGROUND ART

[0002] Generally, in the chemical, food or fertilizer factory, it isnecessary to control various processes such as supply and reaction ofraw material. In order to control various devices (equipment andmachinery) for a process unit, the PLC (Programmable logic controller)linking up with the various devices is used.

[0003] Since the PLC is connected with the various devices of theprocess unit, and a computer, a user confirms an advancing state of aprocess in the process unit controlled by the PLC through a computerdisplay.

[0004] In other words, the devices carry out actions such as weighingand feeding processes of raw material, and the controls of temperature,pressure, pH, etc.

[0005] Then, in order to control operations of these devices, it isrequired to manually and necessarily change a program of the PLC andsetting values of these devices. To this end, there occur problems inthat it is not easy to set again process parameters of the devices andthus time and labor are wasted due to the resetting of the processparameters.

[0006] Further, the waste in the time and labor causes a lowering inefficiency.

DISCLOSURE OF INVENTION

[0007] The present invention has been devised to solve the aboveproblems, and it is an object of the invention to allow constitution andsetting of various devices for a process unit to be carried out on acomputer display.

[0008] It is another object of the invention to group or arrangeoperations of various devices into a unit process and to operate andcontrol the grouped unit processes smoothly.

[0009] It is further another object of the invention to rearrangedevices and change set values of process parameters with ease.

[0010] To accomplish the above objects and other features, there isprovided a factory automation control method comprising the steps of:constituting and setting various devices for a process unit on acomputer display; grouping the various devices into a transfer line, aheating line and a cooling line; selecting at least one of the threegrouped lines to set a control loop for a parameter includingtemperature, pressure, flow rate, pH and level and dropping; performingdata input relating to a process operation; executing a simulatedoperation and debugging some input errors; and connecting the variousdevices to the computer via a PLC and normally operating the variousdevices.

[0011] Preferably, the method, between the step of constituting andsetting the various devices and the step of grouping the variousdevices, further comprises steps of: inputting a level window; anddirectly controlling numeric value using a numeric value control button.

[0012] Preferably, the step of inputting the level window comprisingsteps of designating a corresponding indication window in which a gaugeadjustment is completed; connecting a corresponding data with aregistration information of the corresponding indication window; andsetting a level picture of the level window to be moved depending on anumeric value of the indication window.

[0013] Preferably, the method, between the step of constituting andsetting the various devices and the step of grouping the variousdevices, further comprises a contact point confirming step of confirmingthe settings up to the now.

[0014] Preferably, the step of inputting and setting the various devicescomprises the steps of: selecting the various devices of the processunit and positioning the selected devices on the computer display;controlling a detail specification of the selected devices andcompleting a registration of the device on the computer display;selecting a pipe line connecting the various devices, positioning theselected devices on the computer display, and selecting and positioningan appropriate valve among various valves at a predetermined position ofthe pipe line; selecting a numeric value indication window fordisplaying analog input/output data and digital input signals andpositioning the selected numeric value indication window outside thedevices; designating a contact point on the digital input signals and acontact point on a digital output; and inputting a minimum value or amaximum value on the all analog input data, or carrying out a pulseinput to thereby complete the gauge adjustment.

[0015] Preferably, the method, between the step of designating thecontrol loop and the step of performing the input relating to theprocess operation, further comprises steps of setting a digital input,designating pulse and designating a timer.

[0016] Preferably, the method, after the step of designating the timer,further comprises steps of setting a safety condition for a safe processoperation and setting a condition on an overload of a motor.

[0017] Preferably, the method further comprises an operation standbyfunction to prevent the transfer lines from being driven at the sametime.

[0018] Preferably, the step of designating the control loop comprisesautomation control for constantly maintaining an inner temperature,pressure, flow rate, pH and level of the various devices.

[0019] Preferably, the method further comprises a dropping function fordesignating the transfer line and the control indication window suchthat raw material is supplied into the devices at a constant rate whilethe process condition of the devices is constantly maintained.

[0020] Preferably, the method further comprises a next button selectionfunction which allows a next process step to be continuously performedby selecting and designating a process number.

BRIEF DESCRIPTION OF DRAWINGS

[0021]FIG. 1 is a block diagram of a factory automation control systemin accordance with one embodiment of the present invention;

[0022]FIG. 2 is a flow diagram showing input and setting procedures ofvarious devices of a process unit on a computer display using the systemof FIG. 1; and

[0023]FIG. 3 is a flow diagram showing an automatic operation procedureof a process according to the process flow set in FIG. 2.

BEST MODE FOR CARRYING OUT THE INVENTION

[0024] Hereinafter, there are described in detail preferred embodimentsof the present invention with reference to the accompanying drawings.

[0025]FIG. 1 is a block diagram of a factory automation control systemin accordance with one embodiment of the present invention, FIG. 2 is aflow diagram showing input and setting procedures of various devices fora process unit on a computer display using the system of FIG. 1 and FIG.3 is a flow diagram showing an automatic operation procedure of aprocess according to the process flow set in FIG. 2.

[0026] The present invention is applied to an automation operationcontrol system in a chemical factory or other factories. As shown inFIG. 1, an automation operation control system of the present inventionincludes a process unit 30 provided with various process devices, i.e.,reactor, tank, pump, motor, screw, centrifuge, heat exchanger, boiler,refrigerator, cooling tower, filter, conveyor, evaporator, crusher,mixer, dust collector, tower, switch, valve, pipe and so on, a PLC 20linked with the various devices of the process unit, and a computer 10provided with a program for changing the devices and a setting of aprocess operation.

[0027] By using the system having the constitution of FIG. 1, thevarious devices of the process unit are inputted and set through amonitor of the computer 10. After that, according to the setconstitution, processes are automatically operated.

[0028] First, there is described a procedure for inputting and settingthe various devices of the process unit on the monitor of the computer10 with reference to FIG. 2.

[0029] Referring to FIG. 2, the various devices of the process unit areselected and the selected devices are arranged on the monitor of thecomputer 10.

[0030] Afterwards, detailed specifications of the selected devices areadjusted on the monitor of the computer 10, thereby completingregistration of the various devices.

[0031] Thereafter, pipe lines for connecting the various devices witheach other are selected and the selected pipe lines are arranged on themonitor of the computer 10. Then, among various valves, one valveappropriate for a selected process is selected and the selected valve isdisposed at a predetermined position on the pipe line.

[0032] Afterwards, a numeric indicator window for displaying analoginput and output data and digital input signal is selected and isdisposed at an edge of the monitor around the various devices.

[0033] Next, a contact point (switch) for a digital output is designatedwhile a contact point for the above signal is designated. Thereafter,minimum and maximum values for all analog data and pulse input data areinputted, thereby completing gauge adjustment.

[0034] After the completion of the gauge adjustment, it is possible toadd a level window for easier confirmation of a process state. In thiscase, a corresponding indicator window of which the gauge adjustment iscompleted is designated to connect the registration information of thecorresponding level window, in which level drawing of the level windowis moved depending on the numeric value of the indicator window.

[0035] In addition, after one among the indicator windows of which thegauge adjustment is completed is connected with the numeric value inputbutton (INC and DEC buttons), it is possible to directly adjust allanalog input and output values. And the numeric value of the pulse inputwindow can be changed through the monitor of the computer 10.

[0036] In order to confirm all values set until now, a step ofconfirming the contact point can be additively performed. For theconfirmation of the contact points, a necessary letter is inputted onthe monitor of the computer 10 while non-designated contact points areconfirmed using a contact point view button.

[0037] After the process constitution is completed like the above, asetting procedure for the process automation operation is carried out,and is described with reference to FIG. 3.

[0038] Referring to FIG. 3, in order to operate the various devices ofthe process unit in which the process constitution is completed, devicesused in respective work steps, and corresponding indicator windows arepreviously designated depending on their characteristic, and are groupedinto a transfer line, a heating line and a cooling line. Among thegrouped transfer line, heating line and cooling line, at least one lineis set. Then, a control loop for process control parameters such astemperature, pressure, flow rate, pH and level, dropping and so on isset. Selectively, it is possible to carry out digital input (DI)setting, pulse setting, timer setting, safety setting for safe operationof a process, and overload (OL) setting of motors, only with on themonitor screen of the computer 10.

[0039] If the line setting and the control loop setting are completed,the input work related with the process operation is carried out. Then,a simulated operation is executed and thereby an input error isdebugged.

[0040] If the debugging work of the input error is completed, thevarious devices are on-line connected with the PLC and the computer, andare normally operated.

[0041] Hereinafter, terminologies mentioned in the present invention aredefined, and the aforementioned individual procedures are specificallydescribed.

[0042] Line and Line set: Line is meant by an individual group having aspecial object and function and made by combination of pre-designatingdevices and corresponding indicator windows to be used in respectivework steps. Line set is meant by the step of combining designatingdevices and indicator windows to be included in this line. As a kind ofthe line, there are the transfer line, the heating line and the coolingline as mentioned above.

[0043] Control loop and Control loop set: Loop is meant by individualgroups made by previously designating one of the lines made in the lineset, indicator windows indicating control parameters and main valves tobe used for the control. Control loop set is meant by the step ofdesignating kinds of lines, corresponding indicator window and mainvalve constituting the loop.

[0044] It is possible to set a control loop for temperature, pressure,flow rate, pH and level, and dropping.

[0045] Thus, if the respective lines and loops are set, it is possibleto carry out inputs for all process works with ease only by calling thenumbers of the preset lines and loops.

[0046] As the line set step, there are a transfer line set for carryingout setting devices such as automatic valves, pumps and the like thatshould be operated when it is necessary to automatically weigh andtransfer raw material, a heating line set for carrying out settingdevices used for elevating temperature of the process devices or processraw material, and a cooling line set for carrying out setting devicesused for the cooling.

[0047] As the control loop set step, there are a temperature loop set, apressure loop set, a flow rate loop set, a pH loop set, a level loop setand a dropping set. The temperature loop set designates correspondingheating line or cooling line for the temperature control of a device ora substance, and also designates main valve and temperature indicatorwindow to be used in the designated lines. The pressure loop settransfer line, main valve and pressure indicator window which should beturned on or off when it is necessary to control pressure of a device byapplying vacuum or pressure. The flow rate loop set designates transferline, main control valve and flow rate indicator window which should beturned on or off in order to control flow rate when it is necessary totransfer vapor or liquid. The pH loop set designates transfer line, mainvalve and pH indicator window which should be turned on or off in orderto put acid or alkaline solution when it is necessary to control pH ofliquid substance. The level loop set designates transfer line, mainvalve and level indicator windows (height, volume, weight, etc.) whichshould be turned on or off in order to control a level of liquidsubstance. The dropping set designates corresponding transfer lines andcorresponding indicator windows (temperature, pressure, pH, etc.) whenit is necessary to feed a chemical substance (raw material) to a deviceof a process unit (i.e., chemical device) while temperature, pressure,pH, etc., of a chemical device are maintained at a constant value.

[0048] In addition to the aforementioned sets, there are a digital inputset, a pulse set, a timer set, and a safety set. The digital input setdesignates a relationship between the digital input (DI) signal and thedigital output signal (DO). The pulse set designates a switch to beinstantaneously turned on and then turned off when the switch receivesON command. The timer set designates a timer such that a switch isalternately and repeatedly turned on or off at a constant interval whenthe switch receive ON command. The safety set designates switches thatshould be turned on at the same time or that should not be turned on atthe same time, or designates switches that should be turned on or offwhen an analog input numeric value reaches a maximum.

[0049] Next, there are concretely described respective lines and loopsin the line set step and the control loop set step.

[0050] In order to automatically weigh and transfer chemical material inchemical processes, the transfer line designates devices including pump,automatic valve, etc., and indicator window (select one of indicatorwindows of weight, flow rate, volume, digital input, etc.) sequentiallyand is grouped as one transfer line. The line is called and designatedduring a process input step. As a consequence, during the execution of areal process, the switches designated in the line are turned on or offin the order designated, and reads and determines a variation in numericvalue in the indicator window designated by the computer by itself.Then, if the amount designated during the process input step istransferred, the designated switches are turned on or off, therebycompleting the works of the transfer line.

[0051] Next, the procedure of the transfer line designation is asfollows:

[0052]1. In the step 1, switches which should be turned on or off inorder to transfer chemical substances are designated according to afixed order;

[0053]2. In the step 2, an indicator window for measuring a transferamount is designated; and

[0054]3. In the step 3, switches which should be turned on or off forthe completion of the transfer are designated according to a fixedorder.

[0055] The above designations are carried out by clicking mouse on acomputer or pressing keyboard.

[0056] Like the above, the transfer lines have several kinds ofoperation characteristics depending on the designation types.

[0057] First, during the procedure of the transfer line designation, incase that after the designation of the switches (step 1), only theindicator windows are designated (step 2) and the item of step 3 isomitted, after the transfer of the designated amount is completed inactual plant operations, all of the switches which were designated to beturned on at step 1 are all turned off.

[0058] Second, in case that the three setting steps are all designated,after the transfer of the designated amount is completed, only theswitches which were designated to be turned on/off at step 3 are turnedon/off.

[0059] Also, in case that only the switches are designated, i.e., incase that only the step 1 is designated, if this line is called in aprocess, the designated switches perform only ON or OFF, and no weighingis performed.

[0060] Further, in case that a transfer line designated to the step 2 orstep 3 is called for only simple ON/OFF action, the computer determinessuch action by itself, and performs the only ON/OFF action for theswitches designated in the step 1.

[0061] When two independent processes are operated and there is a devicein a transfer line which is designated to operate at the same time inthe two independent processes, a subsequent one of the two independentprocesses has the operation standby function waiting for a first startedprocess to be ended, the operation standby function being contained inthe transfer line. In other words, if the transfer line is called,switches which should be turned on or off are checked out before thetransfer line is operated. If one of these switches is in on-state, thissystem has a function in which it waits until the on-state switch isturned off, and allows for the transfer line to be operated if theon-state switch is changed to the turn-on state, thereby preventing acollision between the transfer lines.

[0062] By using the operation standby function, in two completelyindependent transfer lines which should not be operated at the sametime, an imaginary switch can be made on the screen of the computer. Bydesignating the imaginary switch in On-state, it can be prevented thatthe two completely independent transfer lines are operated at the sametime.

[0063] The heating line is used for heating a device or a substance. Forthis purpose, switches which should be turned on or off are designatedaccording to a fixed order. Also, a temperature indicator window fordisplaying the temperature upon heating is designated. The switches andthe temperature indicator window are grouped by one line. After thegrouped one line is designated in a temperature loop, if the loop iscalled in a process, this heating line is operated.

[0064] The cooling line is used for cooling a device or a substance. Forthis purpose, switches which should be turned on or off are designatedaccording to a fixed order. Also, a temperature indicator window fordisplaying the temperature upon cooling is designated. The switches andthe temperature indicator window are grouped by one line. After thegrouped one line is designated in a temperature loop, if the loop iscalled in a process, this cooling line is operated.

[0065] The temperature loop is operated when the temperature loop iscalled in a process, after the switches and the indicator windows thatwere designated in the heating line and the cooling line are designatedin a temperature loop. The temperature loop is designated in the orderin which first a corresponding temperature indicator window isdesignated, second the heating line or the heating line is selected, andlast a main valve to be used in the temperature control is selected.

[0066] Operation of the temperature loop is characterized in that ifON/OFF valve is designated as the main valve, a control output isON/OFF, i.e., a digital signal is sent as control output, or if thecontrol valve is designated as the main valve, 4-20 mA, i.e., an analogsignal is sent as control output.

[0067] The pressure loop is operated for vacuum or pressure is appliedto a device when the loop is called in a process after a transfer lineand a corresponding pressure indicator window are designated as a singlepressure loop.

[0068] The pressure loop is designated in the order in which first acorresponding pressure indicator window is designated, second acorresponding transfer line is designated, and last a main valve tocontrol pressure is selected.

[0069] Operation of the pressure loop is characterized in that if ON/OFFvalve is designated as the main valve, a control output is ON/OFF, i.e.,a digital signal is sent as control output, or if the control valve isdesignated as the main valve, 4-20 mA, i.e., an analog signal is sent ascontrol output. At this time, in the case that the indicator window ofweight, volume and so on is designated in the designated transfer line,only the switches designated at step 1 of the procedure of the transferline designation are turned on or off.

[0070] Further, when a corresponding pressure indicator window isdesignated, if an indicator window having a unit of torr is selected thepressure loop is carried out in a vacuum process, or if an indicatorwindow having a unit of kg-f is selected, the pressure loop is carriedout in a pressure application process.

[0071] The flow rate loop is operated when the flow rate loop is called,after a transfer line and a corresponding flow rate indicator window aredesignated as the flow rate loop.

[0072] The flow rate loop is designated in an order in which acorresponding transfer line is designated, and a main control valve forcontrolling flow rate is selected.

[0073] Operation of the flow rate loop is characterized in that whenindicator window of weight, volume and so on is designated in thedesignated transfer line, only the switches designated at step 1 of theprocedure of the transfer line designation are turned on or off.

[0074] The pH loop is operated in order to feed acid or alkalinesolution and to control pH of a liquid substance when the pH loop iscalled in a process, after a transfer line in which devices which shouldbe turned on or off, and a corresponding pH indicator window aredesignated as the pH loop.

[0075] The pH loop is designated in an order in which a corresponding pHindicator window is designated, a corresponding transfer line isdesignated, and a main valve to control pH is selected.

[0076] Operation of the pH loop is characterized in that in case thatindicator window of weight, volume and so on is designated in thedesignated transfer line, only the switches designated at step 1 of theprocedure of the transfer line designation are turned on or off.

[0077] Further, if the control valve is selected as the main valve, thecontrol valve is operated in two types of operations, i.e., 0% and 100%.

[0078] The level loop is operated when the level loop is called, after atransfer line and a corresponding level indicator window (height, volumeand weight) are designated as the level loop.

[0079] The level loop is designated in an order in which a correspondinglevel indicator window is designated, a corresponding transfer line isdesignated and a main valve for controlling the level is selected.

[0080] Operation of the level loop is characterized in that if theON/OFF valve is designated as the main valve, a control output isON/OFF, i.e., a digital signal is sent, or if the control valve isdesignated as the main valve, 4-20 mA, i.e., an analog signal is sent ascontrol output.

[0081] At this time, in case that indicator windows of weight, volumeand so on are designated in the designated transfer line, only theswitches designated at the step 1 of the procedure of the transfer linedesignation are turned on or off.

[0082] The dropping line is used for feeding chemical substances at aconstant rate when the chemical substance is fed into various devices ofa process unit while maintaining temperature, pressure, pH and so onwithin the devices at a constant level, and is operated when thedropping line is called after a corresponding transfer line and acorresponding control indicator window (temperature, pressure, pH, etc.)are designated as the dropping line.

[0083] The dropping line is designated in an order in which acorresponding level indicator window is designated, a correspondingtransfer line is designated and a main valve for controlling the levelis selected.

[0084] Operation of the dropping line is characterized in that sincecontrol values inputted in the process input step are a prioritycondition on operating the dropping line, if the control values are notsatisfied, the operation of the dropping line is stopped.

[0085] Further, the transfer line repeatedly operates or stops withminimum time interval as inputted, thereby feeding chemical substance(raw material).

[0086] The DI set is used for defining a relationship between digitalinput signal inputted from a field, i.e., a process unit, and digitaloutput signal.

[0087] The pulse set is set such that when a switch receives ON command,the switch is instantaneously turned on and then turned off.

[0088] The timer set is set such that when a switch receives On command,the switch repeats ON and OFF with constant intervals.

[0089] The safety set (safety loop) is to set switches which should beturned on at the same time, switches which should not be turned on atthe same time, or switches which should be turned on or off when ananalog input value is get to a maximum.

[0090] The motor overload set designates a digital input terminal forreceiving an overload when a motor is overloaded.

[0091] After the line set, the control loop set and so on are completedaccording to the methods described above, a process is registered in aprocess button, and a process input procedure on the registered processis carried out.

[0092] By clicking the “process input” button and pushing button amongthe registered process buttons, the process input is prepared.

[0093] As the process input, there are process button designation,selection of process kind (independent process or sequential process),weighing of raw material, supply of raw material, start and stop ofdropping, transfer of product, start and stop of vacuum line, start andstop of compression line, start and stop of other transfer lines, startand stop of heating process, start and stop of cooling process,maintaining temperature, start and stop of level control, start and stopof pH control, start and stop of individual devices, input of standbytime, standby of digital input, standby of analog input, designation ofnext button, etc.

[0094] Here, the process button designation in the process inputprocedure includes the designation of a button among process buttons(user buttons). By selecting the process input button and one of theprocess buttons (user buttons), the process input is prepared.

[0095] When the independent process is selected, all processes to beinputted later start independently at the same time and endindependently. When all processes are completed, it is regarded thatonce work for a corresponding process button is completed.

[0096] When the sequential process is selected, all processes to beinputted later are sequentially performed according to an inputsequence. If the last process is completed, it is regarded that oncework for a corresponding process button is completed.

[0097] The weighing and supply of raw material are carried out bydesignating a corresponding transfer line and inputting the value of atransfer amount. At this time, in case that the indicator windowdesignated in the transfer line is a digital input window, 0 isinputted.

[0098] In the start and stop of the dropping, the dropping work iscarried out by inputting the number of a drop line designated in thestep of the line and control loop set, a total amount to be fed (in casethat weighing is not carried out, 0 is inputted), a total time to befed, a time interval on being fed, and then inputting control value (oneof temperature, pressure, pH and so on).

[0099] If the total amount to be fed is not designated, the droppingstop has to be designated so as to end the dropping work.

[0100] The product transfer is used so as to transfer products orintermediate products, and is carried out by inputting a transfer linenumber, and turning on or off only switches which were designated priorto designating indicator windows in case that an analog input indicatorwindow is designated at the input procedure of the transfer line.

[0101] In the start and stop of the vacuum and compression lines, theoperations of the vacuum and compression within the various devices arecarried out by inputting a predesignated pressure loop number and acontrol pressure.

[0102] The start and stop of the other transfer lines are carried out byinputting start or stop of a line designated as the transfer line, andif an analog input indicator window is designated at the inputtedtransfer line, only switches which were designated prior to designatingindicator windows are turned on or off.

[0103] In the start and stop of the heating and cooling processes, thestart is carried out by sequentially inputting a predesignatedtemperature loop and a control temperature, and the stop is carried outby designating the stop during the control.

[0104] In the maintaining temperature, after it arrives at a controltemperature in the heating or cooling process, if a maintenance time isinputted, the control temperature is maintained at the inputtedmaintaining time.

[0105] In the start and stop of the level control, the start is carriedout by designating an operation of a predesignated level loop andinputting numeric value of a control level, and the stop of the levelcontrol is carried out by designating the stop of the level control.

[0106] In the start and stop of the pH control, the start is carried outby inputting number of a predesignated pH loop, inputting kind of liquidto be fed to control the pH, i.e., acidity or alkalinity, inputting aminimum amount allowed to be fed at once for the control of pH,inputting a time to be stirred after feeding the minimum amount in orderto read the pH value and inputting a pH value for the control.

[0107] The stop of the pH control is carried out by selecting stop ofthe pH control and inputting a number of the pH loop.

[0108] The operation and stop of the individual devices are used toindependently operate a device which the contact point is designated,and are carried out by inputting numbers of the contact points of thedevices, and ON and OFF.

[0109] The input of the standby time is used to input the standby timeafter a previously inputted process is ended, before a next process isperformed. Thus, if the standby time is inputted, the next process is onstandby during the standby time.

[0110] The DI standby input is carried out by inputting a terminalnumber of a digital input signal, and is mainly used in the sequentialprocess. If the DI standby input process is called, the next process iscarried out when the digital input signal of the inputted terminalnumber is changed from OFF to ON, or from ON to OFF.

[0111] The AI standby input is completed by inputting a terminal numberof an analog input signal, inputting whether the analog signal is arising one or a falling one, and inputting an analog numeric value.

[0112] When the operation reaches to the step of AI standby inputprocess and the inputted analog signal arrives at the inputted analognumeric value, the computer proceeds the present process to a next one.

[0113] Conventionally, by inputting standby time or setting a digitalsignal or an analog signal, the process work is proceeded from oneprocess to a next process. However, the present invention makes itpossible to insert a set of processes designated within a button into aset of present processes with ease only by designating the number of aprocess button using the next button designation function.

[0114] During the input of the process, by designating the number of aprocess button to be connected next using the next button function, allprocesses inputted within the process button are carried out. Byselecting “wait the end of this process (1)”, after all processes withinthis button are completely carried out, the present process is proceededto a designated next process, whereas by selecting “No (0)”, a processwithin this button starts simply, and then the process goes to a nextprocess.

[0115] Like the above, if the input of the process is completed, asimulated operation is carried out while an error in the inputtedprocess is confirmed. In other words, the computer carries out asimulated operation in an offline state to the plant if a simulatedoperation button and a corresponding process button are pushed. Throughthe simulated operation, an error in the process input is found andcorrected. If the error correction is completed, an on-line button ispushed to carry out the automated operation of the factory without anoperator.

[0116] Although the present invention has been illustrated withreference to embodiments of the present invention, it should beunderstood that the scope of the present invention is not limited to theillustrated embodiments but various changes, substitutions andalterations could be made hereto without departing from the spirit andscope of the invention as defined by the appended claims.

INDUSTRIAL APPLICABILITY

[0117] As described above, according to the present invention, variousdevices of a process unit are constituted and set on the computer, andthey operate in a grouped unit process, so that the process control andoperation are automatically and smoothly carried out.

[0118] Further, it is easy to change the constitution and setting of thevarious devices.

[0119] Furthermore, since reconstitution and resetting for the variousdevices are performed with ease on the computer, work time and labor aresaved and work efficiency is enhanced.

1. A factory automation control method comprising the steps of:constituting and setting various devices for a process unit on acomputer display; grouping the various devices into a transfer line, aheating line and a cooling line; selecting at least one of the threegrouped lines and setting control loops for parameters includingtemperature, pressure, flow rate, pH and level and dropping; performinginput procedure relating to a process operation; executing a simulatedoperation and confirming an input error; and on-line connecting thevarious devices with the computer and normally operating the variousdevices.
 2. The method of claim 1, between the step of constituting andsetting the various devices and the step of grouping the variousdevices, further comprising steps of: inputting a level window; anddirectly controlling numeric value using a numeric value control button.3. The method of claim 2, wherein the step of inputting the level windowcomprising steps of designating a corresponding indication window inwhich a gauge adjustment is completed; connecting a corresponding datawith a registration information of the corresponding indication window;and setting a level picture of the level window to be moved depending ona numeric value of the indication window.
 4. The method of claim 2,wherein the step of controlling the numeric value comprising the stepsof: connecting a numeric value input button with any one of theindication windows in which a gauge adjustment is completed; anddirectly adjusting numeric values on all analog input/output and pulseinput numeric value indication window by adjusting up and down arrowbuttons of the numeric value input buttons (INC and DEC buttons) on thecomputer display.
 5. The method of claim 1 or 2, between the step ofconstituting and setting the various devices and the step of groupingthe various devices, further comprising a contact point confirming stepof confirming the settings up to the now.
 6. The method of claim 1,wherein the step of inputting and setting the various devices comprisesthe steps of: selecting the various devices of the process unit andpositioning the selected devices on the computer display; controlling adetail specification of the selected devices and completing aregistration of the device on the computer display; selecting a pipeline connecting the various devices, positioning the selected devices onthe computer display, and selecting and positioning an appropriate valveamong various valves at a predetermined position of the pipe line;selecting a numeric value indication window for displaying analoginput/output data and digital input signals and positioning the selectednumeric value indication window around the devices; designating acontact point on the digital input signals and a contact point on adigital output; and inputting a minimum value or a maximum value on theall analog input data to thereby complete the gauge adjustment.
 7. Themethod of claim 1 or 6, between the step of designating the control loopand the step of performing the input relating to the process operation,further comprising steps of setting a digital input, designating pulseand designating a timer.
 8. The method of claim 7, after the step ofdesignating the timer, further comprising steps of setting a safetycondition for a safe process operation and setting a condition on anoverload of a motor.
 9. The method of claim 1 or 6, further comprisingan operation standby function to prevent the transfer lines from beingdriven at the same time.
 10. The method of claim 1 or 6, wherein thestep of designating the control loop comprises automation control forconstantly maintaining an inner temperature, pressure, flow rate, pH andlevel of the various devices.
 11. The method of claim 1, furthercomprising a dropping function for designating the transfer line and thecontrol indication window such that raw material is supplied into thedevices at a constant rate while the process condition of the devices isconstantly maintained.
 12. The method of claim 1, further comprising anext button designation function which allows a next process step to beperformed by selecting and designating a process number.